Electrochemical current collector screen designs utilizing ultrasonic welding

ABSTRACT

An electrochemical cell comprising an electrode assembly having a plurality of cathodes in which the plurality of cathodes is electrically connected together at a connection tab junction is disclosed. The junction preferably comprises a plurality of cathode connection tabs that are folded over each other to construct a junction that is mechanically and electrically robust. The junction is comprised of a plurality of connection tabs that each extend from a cathode. Each of the respective tabs is folded over each other to form a compact electrode junction having redundant connections. An elongated lead extends from the junction to provide an electrical connection to the plurality of cathodes. The junction is welded together such as by a laser, resistance or ultrasonic weld joint. The cathode junction is suitable for either primary or secondary cells, particularly those powering implantable biomedical devices.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation in part of U.S. patent applicationSer. No. 14/028,324, filed Sep. 16, 2013, that claims priority from U.S.Provisional Patent Application Ser. No. 61/701,283, filed Sep. 14, 2012.

FIELD OF THE INVENTION

The present invention relates to the art of electrochemical cells, andmore particularly, to various embodiments of electrode assemblyconstructions that connect multiple cathodes within an electrochemicalcell.

PRIOR ART

The recent rapid development in small-sized electronic devices havingvarious shape and size requirements requires comparably small-sizedelectrochemical cells of different designs that can be easilymanufactured and used in these electronic devices. Preferably, theelectrochemical cell has a high energy density. One commonly used cellconfiguration is a prismatic, case-negative cell design having anintermediate cathode flanked by opposed anode components in contact withthe casing and in electrical association with the cathode.

The diverse variety of materials used in the construction ofelectrochemical cells increases the difficulty of assembling andmanufacturing such small intricate devices. It is desirable to buildsuch electrochemical cells with simplified procedures that create anelectrochemical cell with a durable and robust construction. Suchelectrochemical cells require joining various internal components,composed of differing materials, with a strong durable bond. One ofthese critical connections is that of the current collector to the leador terminal pin. As the name implies, the current collector gathers orcollects the current that is generated within the electrochemical cell.The lead or terminal pin provides an electrical conduit from whichelectrochemical energy from within the cell is transferred external tothe cell.

In the case of a primary electrochemical cell, the cell may comprise ananode current collector, a cathode current collector, or both. The anodeor cathode primary cell current collector typically comprises a sheet ofmetal in the form of either a solid substrate, a mesh or a screen. Inthe case of a secondary cell, the inside surface of the case typicallyacts as the current collector.

However, because of the increasing cell size constraints, there is aneed to minimize the number and the size of the components utilized tocreate electrical connections within the cell. That is while stillproviding robust connections. The present invention, therefore, providesvarious current collector embodiments that may utilize variousconfigurations and weld connections. Specifically, embodiments whichimprove the connection between the current collector and a lead and/or aterminal pin are disclosed. In a preferred embodiment, the variouscurrent collector embodiments utilize an ultrasonic weld connection thatminimizes the number and size of additional connection components.

In addition, the present application provides embodiments of variouselectrode assemblies. Of particular interest is the connection of theelectrodes within an electrode assembly of an electrochemical cell. Itis thus desirable that these electrical connections between electrodes,within the electrode assembly, are also mechanically robust to ensure along lasting electrical connection that is able to withstand thermalexpansion in addition to mechanical shock and vibration. This isparticularly desirable for electrochemical cells that comprise multipleelectrodes, such as multiple cathodes, that are electrically joinedtogether. Furthermore, as cell sizes decrease and as different materialsare utilized within cell constructions, it is desirable to haveconnection sub-assemblies that are compact in size, in addition to beingresistant to thermal expansion and mechanical shock and vibration.

Additionally, the present invention enables the use of cost effectivematerials in the construction of electrochemical cells. Of particularinterest is the current collector which can now be constructed fromvarious cost effective materials such as aluminum. Furthermore, theultrasonic welding process of the present invention is fast, simple,easy to control and effective.

SUMMARY OF THE INVENTION

The present invention relates to various designs of electrochemicalcells. More specifically, the present invention relates to variousdesigns of current collectors that are utilized in the construction ofelectrochemical cells. In addition, the present invention providesvarious current collector embodiments that are adaptable to theutilization of ultrasonic welding to join the current collector to alead or terminal pin. The present invention further relates to methodsof joining a lead or terminal pin to the current collector havingdifferent geometries and configurations that utilize ultrasonic weldingtechniques.

During the ultrasonic welding process, the applied ultrasonic energyimparts a friction between the surfaces of the two materials creating asolid-state bond therebetween. A mechanical force may also besimultaneously applied during the welding process that further enablesjoining of the two materials, i.e., the current collector and a terminalpin. After the vibrational energy is removed, a strong bond between thetwo materials is present. Prior art connections between the currentcollector and the terminal lead generally utilize a resistance weld orlaser weld to connect the terminal pin/lead to the current collector.These prior art welding techniques usually require the use of anintermediary material that facilitates the connection therebetween.Resistance and laser welding techniques generally utilize heat to meltand join materials together. However, differences in materialcompositions and properties sometimes prohibit the formation of a robustand durable bond therebetween. The present invention, unlike the priorart, utilizes ultrasonic energy to join differing materials together.Therefore, other materials that have historically been difficult to joinutilizing laser and resistance welding techniques are now more easilyjoined using ultrasonic welding.

In a preferred embodiment of the present invention, multiple currentcollectors are joined to a lead or terminal pin utilizing ultrasonicwelding. Generally, a current collector is in electrical contact withthe active material that comprises the anode, the active material thatcomprises the cathode, or both. The present invention can also beutilized in a variety of rechargeable or non-rechargeableelectrochemical cell designs and chemistries in both case negative andcase positive designs.

In an embodiment of the present invention, multiple electrodes, such ascathodes, are electrically connected together within an electrodeassembly of an electrochemical cell. More specifically, the cathodes ofthe electrode assembly of the cell are joined together at a junctionthat comprises multiple connection tabs that outwardly extend fromrespective cathodes that comprise the assembly. In a preferredembodiment, this electrode connection is constructed by folding andwelding the various tabs of the cathodes together in a compact junction.Thus, by folding the multiple connection tabs of the cathodes together,a compact and mechanically robust structure having redundant connectionpoints is created. These redundant connections not only ensure amechanically robust connection, but also ensure a robust electricalconnection between the electrodes of the cell.

In a case negative design, the anode is electrically connected to thecasing. In this particular example, the anode material is ultrasonicallywelded to a portion of an interior surface of the case. Alternatively,in a case positive design, the cathode is electrically connected to thecasing. In this particular embodiment, the cathode material may beultrasonically welded to a portion of the interior surface of the case.In either example, the casing may comprise a higher melting temperaturematerial such as titanium, nickel, or stainless steel.

Thus, the present invention overcomes many inherent difficulties inconstructing an electrochemical cell. The present invention reducesmanufacturing cost and reduces construction complexity. Furthermore, thepresent invention provides for an electrochemical cell with a smaller,more compact size than is capable with some other cell designs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of an electrochemicalcell.

FIG. 2 is a cross-sectional view taken from the side illustrating theinternal construction of the electrochemical cell shown in FIG. 1.

FIG. 3 is a side view of an embodiment of a single screen currentcollector of the present invention.

FIG. 3A is a side view of an embodiment of a bi-screen current collectorof the present invention.

FIGS. 4A-4D illustrate various embodiments of a sequence of events informing an electrode assembly of the present invention.

FIG. 5 is a perspective view of an alternate embodiment of an electrodeassembly of the present invention.

FIG. 5A illustrates a magnified perspective view of an embodiment of theelectrode assembly shown in FIG. 5.

FIG. 6 is a side view illustrating an embodiment of the components of anultra sonic welding apparatus.

FIGS. 7A and 7B illustrate partial cross-section side views depicting anembodiment of the present invention of a terminal pin, lead or platebeing joined a connection tab or landing strip of a current collector.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIGS. 1 and 2, there is shown an exemplaryelectrochemical cell 10 incorporating embodiments of the currentcollector of the present invention. As shown in the embodimentillustrated in FIG. 1, cell 10 comprises a casing 12 having spaced apartfirst and second side walls 14 and 16 extending to and meeting withopposed end walls 18 and 20 and a bottom wall 22. The end walls can becurved to provide the casing having an oval cross-section, or they canbe generally planar to provide a rectangular cross-section. Inperspective, electrochemical cell 10 of the illustrated embodiment issimilar to the prismatic electrochemical described in U.S. Pat. No.5,250,373 to Muffoletto et al.

Cell 10 comprises an electrode assembly 24 that further comprises anodecomponents 26, 28 and cathode components 30, 32 prevented fromcontacting each other by a separator membrane 34. The anode components26, 28 are composed of an anode active material 36 that is supported onan anode current collector 38. Similarly, the cathode components 30, 32are composed of an active cathode material 40 that is supported on acathode current collector 42. An active anode material 36, preferablycomposed of lithium, is joined to the anode current collector 38. Morespecifically, the lithium active anode material 36 may be pressed ontothe anode current collector or, alternatively, may be welded to asurface 44 of the anode current collector 38 using an ultrasonic weldingprocess as disclosed in U.S. patent application Ser. No. 13/346,409 toDai which is assigned to the assignee of the present application.

Although lithium is the preferred material, lithium alloys such aslithium silver, lithium aluminum, lithium boron, lithium silver boron,carbon, and combinations thereof may also be used as active anodematerials. Likewise, the active cathode material 40 is supported by aportion of a surface 46 of the cathode current collector 42. The cathodeactive material may be pressed to the surface 46 of the currentcollector 42 or alternatively, may also by welded to the surface 46 ofthe cathode current collector 42 using an ultrasonic welding process.

The embodiment shown in FIG. 2 is commonly referred to in the art as acase negative cell design. Case negative electrochemical cells areconstructed with anode components 26, 28 that are electrically connectedto casing 12 via the anode current collector 38 while the cathodeelectrode components 30, 32 are electrically connected to anelectrically isolated terminal pin 48 via the cathode current collector42. In a preferred embodiment, a proximal end of the terminal pin 48 isconnected to the current collector 38, 42, and a distal end of theterminal pin 48, spaced from the proximal end, preferably extendsoutside the casing 12.

Alternatively, a case positive cell design may be constructed byreversing the connections. In other words, electrically isolatedterminal pin 48 is connected to the anode components 26, 28 via theanode current collector 38 and the cathode components 30, 32 areconnected to the casing 12 via the cathode current collector 42.Furthermore, a case neutral cell design may be constructed comprisingtwo electrically isolated terminal pins 48. Each of the terminal pins 48are connected to respective anode components 26, 28 and cathodecomponents 30, 32. The various embodiments of the electrode assemblies24 disclosed in the present application may be either of a case negativeor case positive design.

Both the anode current collector 38 and the cathode current collector 42are composed of an electrically conductive material. In a preferredembodiment, the anode current collector 38 or the cathode currentcollector 42 may be composed of a material comprising titanium,aluminum, stainless steel, nickel, their associated alloys, and mixturesthereof. Furthermore, it is contemplated that either current collector38, 42 may be composed of stainless steel, tantalum, copper, platinum,gold, cobalt nickel alloys, highly alloyed ferritic stainless steelcontaining molybdenum and chromium, and nickel-, chromium- andmolybdenum-containing alloys.

In a preferred embodiment, the terminal pin 48 may be composed ofaluminum, molybdenum, tantalum, tungsten, and combinations thereof.Alternatively, terminal pin 48 may also be composed of titanium,aluminum, stainless steel, tantalum, copper, platinum, gold, cobaltnickel alloys, highly alloyed ferritic stainless steel containingmolybdenum and chromium, and nickel-, chromium- andmolybdenum-containing alloys.

It should be noted that the electrochemical cell 10 of the presentinvention as illustrated in FIGS. 1 and 2 can be of either arechargeable (secondary) or non-rechargeable (primary) chemistry of acase negative or case positive design. The specific geometry andchemistry of the electrochemical cell 10 can be of a wide variety thatmeets the requirements of a particular primary and/or secondary cellapplication.

FIGS. 3 and 3A, illustrate embodiments of current collectors 50, 52 ofthe present invention. Both embodiments of current collectors 50, 52 maybe used as anode or cathode current collectors 38, 42 supportingrespective active anode and cathode active materials 36, 40 on itssurfaces. As shown, current collectors 50, 52 generally comprise ascreen portion 54 and a connection perimeter portion 56 that isco-planar with and surrounds the screen 54. As shown in FIG. 3, thecurrent collector 50 comprises a connection tab 58 that extendsoutwardly from the connection perimeter portion 56. Preferably, theconnection tab 58 is co-planar with the screen 54 and the connectionperimeter 56. More preferably, the connection tab 58 extendsperpendicularly from the screen 54. It is noted that while screen 54 isillustrated in a rectangular shape, the shape of the screen may be of amultitude of shapes including but not limited to a square, a circle, ahalf circle, an oval, a triangle, or a generic curved shape.

FIG. 3A illustrates an alternate embodiment of a current collector 52.As shown, current collector 52 is a bi-screen current collectorcomprising two opposing screens 54A, 54B. A current collector bridgeportion 60 extends between the opposing screens 54A, 54B electricallyconnecting the screens therebetween. As illustrated, a landing strip orconnection tab 62 extends perpendicularly from the bridge portion 60. Aswill be discussed in a preferred embodiment, when constructed in anelectrochemical cell 10, the bi-screen current collector 52 ispositioned such that the bridge portion 60 is bent along fold axis 64Aand 64B. In a preferred embodiment, fold axis 64A and 64B are positionedperpendicular to the length of the bridge 60 that spans between the twoscreens 54A and 54B. When positioned within respective adjacentcathodes, the bridge portion 60 is bent along these axes such that theopposing screens 54A, 54B are positioned facing each other andperpendicular to the bridge portion 60. Screen, as pertains to thepresent invention, is defined herein as a foil having a solid surface orof a mesh or grid having a series of perforations throughout itssurface. The screen is designed such that the cathode or anode activematerial 40, 36 is supported thereto.

FIGS. 4A through 4D illustrate an embodiment of a sequence of steps thatmay be performed to construct an electrode assembly 66 of the presentinvention. As illustrated in FIG. 4A, an embodiment of the electrodeassembly 66 is shown. As illustrated, the electrode assembly 66comprises an anode 68 and a plurality of cathodes 70. As shown in FIGS.4A through 4D, the anode is constructed having a serpentine-like shapewith a series of folds 69 that each receive at least one of theplurality of cathodes 70. In a preferred embodiment, the series ofspaced apart folds 69 are positioned along a length of the anode 68.These folds 69 are preferably oriented in alternating directions tothereby form the anode 68 in a serpentine orientation. In a preferredembodiment, each of the plurality of alternating folds 69 define a slot71 within which at least one of the plurality of cathodes 70 ispositioned. As illustrated in FIGS. 4A-4D, the plurality of adjacentlypositioned cathodes 70 are positioned within the slot 71 formed by therespective folds 69 of the anode 68. In other words, the folds 69 of theserpentine-like shaped anode 68 weave around each of the plurality ofadjacently positioned cathodes 70.

In a preferred embodiment, each of the cathodes 70 may comprise thesingle screen current collector 50 as shown in FIG. 3. As constructed,the electrode assembly 66 comprises a plurality of cathodes 70 each withthe single screen current collector 50 embedded therewithin. Each of theplurality of cathodes 70 is preferably constructed with a connection tab58 having a length 73 that extends outwardly from the cathode to adistal tab end 75. In addition, the anode 68 preferably comprises spacedapart first and second anode connection tabs 72A, 72B that outwardlyextend from the anode 68. In a preferred embodiment, as shown in FIGS.4A through 4D, the anode 68 may be constructed with a single screencurrent collector 50 embedded therewithin. The proximal ends of each ofthe first and second anode connection tabs 72A, 72B are preferablyconnected to the current collector 50 positioned within the anode 68.

In an embodiment, after the electrode assembly 66 is constructed, theplurality of connection tabs 58 that extend from each of the cathodes 70are folded over each other to construct a cathode connection tabjunction 80 (FIG. 4D). In a preferred embodiment, a first fold 77 iscreated at a first position along the length of the connection tab 58proximal to the respective cathode 70. In an embodiment, the crease ofthe first fold 77 extends about parallel to a width 79 of the cathode 70such that the distal tab end 75 is oriented about perpendicular to thecathode width 79 and first fold 77 (FIG. 4A). As illustrated in theembodiment shown in FIGS. 4A-4C, a first tab portion 81 of the pluralityof cathode tabs 58 extends distally away from the first fold 77. Inaddition, the first tab portion 81 is oriented about perpendicular tothe first fold 77. A second fold 83 is positioned at a second, distalposition from the first fold 77 along the length of the plurality ofcathode tabs 58. As illustrated in the embodiment shown in FIG. 4D, asecond tab portion 85 of the plurality of cathode tabs 58 extendsdistally away from the second fold 83. In addition, the second tabportion 85 is shown oriented about perpendicular to the second fold 83.In a preferred embodiment, the second tab portion 85 extends over thefirst tab portion 81 and towards the first fold 77. As illustrated inFIG. 4D, in a preferred embodiment, the first and second folds 77, 83face each other but are at different elevations with the second fold 83positioned above the first fold 77.

In addition, a lead 74 or terminal pin 48 (shown in FIGS. 1 and 2) ispositioned in electrical contact with the folded connection tabs 58. Forexample, as illustrated in FIGS. 4C and 4D, the lead 74 may bepositioned within the plurality of the folded connection tabs 58.Alternatively, the lead 74 may be electrically connected to the top ofthe junction 80. A first weld connection 76, such as a weld joint formedby an ultrasonic weld, a laser weld, or a resistance weld, is formedconnecting the plurality of folded tabs 58 to the lead 74 or terminalpin 48.

As shown in FIG. 4C, the excess lengths of tabs 58 are preferably cutoff thereby creating a flush edge 78 with the side of the lead 74 orterminal pin 48. FIG. 4D illustrates an embodiment of the finalizedelectrode assembly 66. As shown, once the excess lengths of the tabs 58are removed, the second portions 85 of the tabs 58 are then folded backover each of the first portions 81 of the tabs 58 to thereby create thecathode tab junction 80. In a preferred embodiment, the crease of thesecond fold 83, positioned distal of the first fold 77, extends aboutparallel to the width 79 of the cathode 70. The second fold 83 ispreferably oriented such that the second tab portions 85 extend towardthe first fold 77. A second weld joint 82 may then be formed connectingthe overlapping first and second portions 81, 85 of the tabs 58 and thelead 48 or terminal pin 48.

While it is preferred that the first and second tab portions 81, 85extend about perpendicular from their respective first and second folds77, 83, it is contemplated that either or both of the first and secondtab portions 81, 85 may be oriented at different angles with respect totheir respective folds 77, 83. For example, either or both of the firstand second tab portions 81, 85 may be oriented at an obtuse angle fromtheir respective folds 77, 83. However, in either case, the cathode tabjunction 80 is formed in which at least a portion of the first andsecond tab portions 81, 85 overlap and are in physical contact with eachother. The electrode assembly 66 is then ready to be positioned withinthe case 12. In a preferred embodiment, at least one of the first andthe second anode connection tabs 72A, 72B is positioned in electricalcontact with an interior surface of the casing 12.

The structure of the cathode connection tab junction 80 ensures amechanically robust connection of the plurality of cathodes 70 thatcomprise the cell 12. Thus, folding the connection tabs 58 of therespective cathodes 70 over each other provides a mechanically durableconnection having redundant connections therebetween. For example, inthe unlikely event that a connection tab may become detached from thejunction 80, the other multiple folded over portions of the cathodeconnection tabs 58 that comprise the junction 80 ensure a continueddurable mechanical and electrical connection of the cathodes 70 thatcomprise the electrode assembly 66. This structure, therefore, providesa mechanically durable connection that can withstand mechanical shockand vibration in addition to thermal expansion. In addition,constructing the junction 80 by folding the various cathode connectiontabs 58 over each other conserves space within the electrode assemblyand the cell casing. Therefore, even smaller electrochemical cell sizesare able to be constructed.

Prior art cells such as the cell disclosed in U.S. Pat. No. 5,716,735 toMuffoletto et al, which is incorporated herein by reference, utilize atraverse bar that is positioned across electrode leads. This prior artconstruction, unlike the embodiment of the present application, lacksthe robust mechanical construction of the present embodiment. Asdisclosed in the '735 patent, there is only one point of contact foreach electrode to the transverse bar that comprises the electrodeassembly. Unlike the present embodiment shown in FIG. 4D, the traversebar construction of the prior art lacks redundant connections that areachieved by overlapping the connection tabs 58. Therefore, if a portionof the transverse bar became detached from an electrode, electricalconnection may be lost. Furthermore, the prior art transverse barconstruction having multiple electrode connections that extend along thelength of the bar occupies a greater amount of space in the cell casingthan the present embodiment which comprises a compact junction ofmultiple folded over tabs 58.

It is noted that while it is preferred that electrode assembly 66 beconstructed such that cathode plate 70 is positioned within the folds ofanode 68, electrode assembly 66 may also be constructed in a plate-likeform. More specifically, electrode assembly 66 may be constructed suchthat both the anode 68 and the cathode 70 comprise a plate-like shapepositioned adjacent each other, such as illustrated in the electrodeassembly embodiment 24 shown in FIG. 2.

As defined herein, a “lead” is a conductive body having two respectiveends that facilitates the transfer of electrochemical energy along alength of the body from one end to the other. A lead may in the form ofa wire, a flat tape, or other electrically conductive body. One end ofthe lead is electrically connected to the electrode assembly,particularly the cathode or anode current collector of the electrodeassembly, and the other end is electrically connected to anotherlocation that may be internal or external of the electrochemical cell.

In a preferred embodiment, lead 74 may be composed of a materialcomprising titanium, aluminum, stainless steel, nickel, their associatedalloys, and mixtures thereof. Furthermore, it is contemplated that thelead 74 may also be composed of stainless steel, tantalum, copper,platinum, gold, cobalt nickel alloys, highly alloyed ferritic stainlesssteel containing molybdenum and chromium, and nickel-, chromium- andmolybdenum-containing alloys.

FIG. 5 illustrates an alternate embodiment of an electrode assembly 84.Like the electrode assembly embodiments 24, 66 previously described,electrode assembly 84 comprises an anode 86 and a cathode 88. However,unlike the previously described electrode assemblies 24 (FIG. 2) and 66(FIGS. 4A-4D), electrode assembly 84 comprises the “bi-screen” currentcollector 52 previously shown in FIG. 3A. Similarly to the electrodeassembly 66 shown in FIG. 4A, electrode assembly 84 preferably comprisesan anode 86 formed in a serpentine orientation. A series of cathodes 88are preferably positioned in between each of the folds of the anode 86.However, in this electrode assembly embodiment 84, the first and secondscreens 54A, 54B of the bi-screen current collector 52 (FIG. 3A) arepositioned within adjacent cathode plates 88. As shown, an imaginaryplane co-planar to the top surface the bridge portion 60 of the currentcollector 52 is positioned about perpendicular to a vertical axis of thecathode plates 88. As shown, the landing strip 62 extends outwardly fromthe bridge portion 60 of the current collector 52. In a preferredembodiment, a distal end of the landing strip 62 extends perpendicularlyfrom the bridge portion 60 of the current collector 52. A proximal endof the landing strip 62 is preferably co-planar to the bridge portion 60of the current collector 52. In a preferred embodiment, the landingstrip 62 is designed to be bendable. As illustrated in FIGS. 5 and 5A,the landing strip 62 is illustrated as being bent at about a 90° anglewith respect to the top surface of the bridge portion 60.

In an embodiment shown in FIG. 5A, a plate 90 may be positioned acrossthe bent landing strips 62 thereby providing a surface with which tocontact the lead(s) 74 or terminal pin(s) 48. In a preferred embodiment,the plate 90 may be ultrasonically welded to at least one of the landingstrips 62. As shown an ultrasonic weld connection 92 connects the plate90 to the landing strips 62. Alternatively, the plate 90 may beconnected to the landing strips 62 using a different means such as alaser or resistance weld.

In a preferred embodiment, the plate 90 may be of a material comprisingtitanium, aluminum, stainless steel, nickel, their associated alloys,and mixtures thereof. Furthermore, it is contemplated that the plate 90may also be composed of stainless steel, tantalum, copper, platinum,gold, cobalt nickel alloys, highly alloyed ferritic stainless steelcontaining molybdenum and chromium, and nickel-, chromium- andmolybdenum-containing alloys.

Furthermore, while it is preferred that electrode assembly 84 beconstructed such that cathode plate 88 is positioned within the folds ofanode 86, electrode assembly 84 may also be constructed in a plate-likeform. More specifically, electrode assembly 84 may be constructed suchthat both the anode 86 and the cathode 88 comprise a plate-like shapethat is positioned adjacent each other, such as illustrated in theelectrode assembly embodiment 24 shown in FIG. 2.

Weld connections 76, 82 and 92 are preferably established through theuse of an ultrasonic welding apparatus 94 illustrated in FIG. 6. Asillustrated, the ultrasonic welder 94 comprises a transducer portion 96,a booster portion 98, and a horn portion 100. The ultrasonic welder 94is connected to a power source 102 such as an electrical power source.

In operation, as shown in the embodiment of FIGS. 7A and 7B, a portionof the terminal pin 48 or lead 74 or plate 90 is placed on a portion ofthe current collector 50, 52. More specifically, as illustrated in FIG.7A, a portion of the terminal pin 48, lead 74 or plate 90 is placed on aportion of a top surface 104 of the connection tabs 58 of currentcollector 50 or landing strips 62 of current collector 52.Alternatively, as shown in FIG. 7B, the terminal pin 48, lead 74 orplate 90 may be positioned such that it contacts a bottom surface 106 ofthe connection tabs 58 of current collector 50 or landing strips 62 ofcurrent collector 52. The combination of either the terminal pin 48,lead 74 or plate 90 and connection tab 58 or landing strip 62 ispositioned on a hard surface such as that of a top surface 105 of ananvil 108.

Once the ultrasonic welder 94 is energized, the horn portion 100 of thewelder 94 is placed in contact with a top surface 110 comprising theterminal pin 48, lead 74 or plate 90 as illustrated in FIG. 7A.Alternatively, as shown in FIG. 7B, the horn 100 of the ultrasonicwelder instrument 94 is placed in contact with a top surface 112 ofeither of the connection tab 58 of current collector 50 or landing strip62 of current collector 52. In either case, the oscillation of the hornportion 100 imparts friction between the top and bottom layers that areto be welded together. The friction created between the top and bottomlayers, i.e., that of the terminal pin 48, lead 74 or plate 90 and thesurface of the connection tab 58 or landing strip 62 as shown in FIG. 7Aor that of the connection tab 58 or landing strip 62 and terminal pin48, lead 74 or plate 90 as shown in FIG. 7B, initially cleans therespective surfaces.

Continued application of the oscillating horn portion 100 imparts africtional energy that generates a solid-state bond between the layersof material at the weld interface. In a preferred embodiment, theultrasonic welder 94 is energized to a welding energy output that rangesfrom about 1 joule to about 100 joules. In addition, when energized, thehorn portion 100 preferably oscillates at a frequency ranging from about20 kHz to about 40 kHz. When energized, the horn portion 100 may have anamplitude that ranges from about 1 μm to about 50 μm. Amplitude isherein defined as the distance the horn 100 travels from an initialposition to a second position when energized. In other words, amplitudeis the lateral distance travelled by the horn 100 when it oscillatesfrom an initial position to a second position that is lateral of theinitial position.

A mechanical force 114 ranging from about 1 lb-force to about 100lb-force may be applied to the horn portion 100 of the ultrasonic welder94 in a downward direction against the anvil 108. The mechanical force114 is preferably applied while the ultrasonic welder 94 is energized.Application of the mechanical force preferably keeps the layers ofmaterial in close contact and helps encourage the weld jointtherebetween.

As previously mentioned, the present invention is applicable to eitherprimary or secondary electrochemical cells. A primary electrochemicalcell that possesses sufficient energy density and discharge capacity forthe rigorous requirements of implantable medical devices comprises alithium anode or its alloys, for example, Li—Si, Li—Al, Li—B andLi—Si—B. The form of the anode may vary, but preferably it is of a thinsheet or foil.

The active cathode material 40 of a primary cell is of electricallyconductive material, preferably a solid material. In a preferredembodiment, the active cathode material 40 may be of a sheet or foilform. Furthermore, the cathode material 40 may comprise a metal element,a metal oxide, a mixed metal oxide and a metal sulfide, and combinationsthereof. A preferred cathode active material is selected from the groupconsisting of silver vanadium oxide, copper silver vanadium oxide,manganese dioxide, cobalt nickel, nickel oxide, copper oxide, coppersulfide, iron sulfide, iron disulfide, titanium disulfide, coppervanadium oxide, and mixtures thereof.

Before fabrication into an electrode for incorporation into anelectrochemical cell, the cathode active material is mixed with a bindermaterial such as a powdered fluoro-polymer, more preferably powderedpolytetrafluoroethylene or powdered polyvinylidene fluoride present atabout 1 to about 5 weight percent of the cathode mixture. Further, up toabout 10 weight percent of a conductive diluent is preferably added tothe cathode mixture to improve conductivity. Suitable materials for thispurpose include acetylene black, carbon black and/or graphite or ametallic powder such as powdered nickel, aluminum, titanium andstainless steel. The preferred cathode active mixture thus includes apowdered fluoro-polymer binder present at about 3 weight percent, aconductive diluent present at about 3 weight percent and about 94 weightpercent of the cathode active material.

The cathode component 30, 32 may be prepared by rolling, spreading orpressing such that it is generally of a sheet or foil form. The cathodeelectrode material 40 may be pressed onto the surface of the cathodecurrent collector 42 or alternatively, the cathode electrode materialmay be welded to the surface of the cathode current collector 42. Thecathode material may also be prepared in the form of a strip wound witha corresponding strip of anode material in a structure similar to a“jellyroll” or a flat-folded electrode stack.

In order to prevent internal short circuit conditions, the cathode 30,32 is separated from the anode 26, 28 by the separator membrane 34. Theseparator membrane 34 is preferably made of a fabric woven fromfluoropolymeric fibers including polyvinylidine fluoride,polyethylenetetrafluoroethylene, and polyethylenechlorotrifluoroethyleneused either alone or laminated with a fluoropolymeric microporous film,non-woven glass, polypropylene, polyethylene, glass fiber materials,ceramics, polytetrafluoroethylene membrane commercially available underthe designation ZITEX (Chemplast Inc.), polypropylene membranecommercially available under the designation CELGARD (Celanese PlasticCompany, Inc.) and a membrane commercially available under thedesignation DEXIGLAS (C. H. Dexter, Div., Dexter Corp.).

A primary electrochemical cell includes a nonaqueous, ionicallyconductive electrolyte having an inorganic, ionically conductive saltdissolved in a nonaqueous solvent and, more preferably, a lithium saltdissolved in a mixture of a low viscosity solvent and a highpermittivity solvent. The salt serves as the vehicle for migration ofthe anode ions to intercalate or react with the cathode active materialand suitable salts include LiPF₆, LiBF₄, LiAsF₆, LiSbF₆, LiClO₄, LiO₂,LiAlCl₄, LiGaCl₄, LiC(SO₂CF₃)₃, LiN(SO₂CF₃)₂, LiSCN, LiO₃SCF₃,LiC₆F₅SO₃, LiO₂CCF₃, LiSO₆F, LiB(C₆H₅)₄, LiCF₃SO₃, and mixtures thereof.

Suitable low viscosity solvents include esters, linear and cyclic ethersand dialkyl carbonates such as tetrahydrofuran (THF), methyl acetate(MA), diglyme, trigylme, tetragylme, dimethyl carbonate (DMC),1,2-dimethoxyethane (DME), 1,2-diethoxyethane (DEE),1-ethoxy,2-methoxyethane (EME), ethyl methyl carbonate, methyl propylcarbonate, ethyl propyl carbonate, diethyl carbonate, dipropylcarbonate, and mixtures thereof. High permittivity solvents includecyclic carbonates, cyclic esters and cyclic amides such as propylenecarbonate (PC), ethylene carbonate (EC), butylene carbonate,acetonitrile, dimethyl sulfoxide, dimethyl, formamide, dimethylacetamide, γ-valerolactone, γ-butyrolactone (GBL),N-methyl-pyrrolidinone (NMP), and mixtures thereof. The preferredelectrolyte for a lithium primary cell is 0.8M to 1.5M LiAsF₆ or LiPF₆dissolved in a 50:50 mixture, by volume, of PC as the preferred highpermittivity solvent and DME as the preferred low viscosity solvent.

By way of example, in an illustrative case negative primary cell, theactive material of cathode body is silver vanadium oxide as described inU.S. Pat. Nos. 4,310,609 and 4,391,729 to Liang et al., or copper silvervanadium oxide as described in U.S. Pat. Nos. 5,472,810 and 5,516,340 toTakeuchi et al., all assigned to the assignee of the present invention,the disclosures of which are hereby incorporated by reference.

In secondary electrochemical systems, the anode 26, 28 comprises amaterial capable of intercalating and de-intercalating the alkali metal,and preferably lithium. A carbonaceous anode comprising any of thevarious forms of carbon (e.g., coke, graphite, acetylene black, carbonblack, glassy carbon, etc.), which are capable of reversibly retainingthe lithium species, is preferred. Graphite is particularly preferreddue to its relatively high lithium-retention capacity. Regardless theform of carbon, fibers of the carbonaceous material are particularlyadvantageous because they have excellent mechanical properties thatpermit them to be fabricated into rigid electrodes capable ofwithstanding degradation during repeated charge/discharge cycling.

The cathode 30, 32 of a secondary cell preferably comprises a lithiatedmaterial that is stable in air and readily handled. Examples of suchair-stable lithiated cathode materials include oxides, sulfides,selenides, and tellurides of such metals as vanadium, titanium,chromium, copper, molybdenum, niobium, iron, nickel, cobalt andmanganese. The more preferred oxides include LiNiO₂, LiMn₂O₄, LiCoO₂,LiCo_(0.92)Sn_(0.08)O₂ and LiCo_(1-x) Ni_(x)O₂.

The lithiated active material is preferably mixed with a conductiveadditive selected from acetylene black, carbon black, graphite, andpowdered metals of nickel, aluminum, titanium and stainless steel. Theelectrode further comprises a fluoro-resin binder, preferably in apowder form, such as PTFE, PVDF, ETFE, polyamides and polyimides, andmixtures thereof.

Suitable secondary electrochemical systems are comprised of nonaqueouselectrolytes of an inorganic salt dissolved in a nonaqueous solvent andmore preferably an alkali metal salt dissolved in a quaternary mixtureof organic carbonate solvents comprising dialkyl (non-cyclic) carbonatesselected from dimethyl carbonate (DMC), diethyl carbonate (DEC),dipropyl carbonate (DPC), ethyl methyl carbonate (EMC), methyl propylcarbonate (MPC) and ethyl propyl carbonate (EPC), and mixtures thereof,and at least one cyclic carbonate selected from propylene carbonate(PC), ethylene carbonate (EC), butylene carbonate (BC) and vinylenecarbonate (VC), and mixtures thereof. Organic carbonates are generallyused in the electrolyte solvent system for such battery chemistriesbecause they exhibit high oxidative stability toward cathode materialsand good kinetic stability toward anode materials.

The casing header comprises a metallic lid 116 (FIGS. 1 and 2) having anopening to accommodate a glass-to-metal seal 118 and terminal pinfeedthrough 48 for the cathode. An additional opening 120 is providedfor electrolyte filling. The casing header comprises elements havingcompatibility with the other components of the electrochemical cell andis resistant to corrosion. The cell is thereafter filled with theelectrolyte solution described hereinabove and hermetically sealed suchas by close-welding a titanium plug over the fill hole, but not limitedthereto.

Now, it is therefore apparent that the present invention has manyfeatures among which are reduced manufacturing cost and constructioncomplexity. While embodiments of the present invention have beendescribed in detail, it is for the purpose of illustration, notlimitation.

What is claimed is:
 1. An electrochemical cell, the cell comprising: a)a casing; b) an electrode assembly contained within the casing, theelectrode assembly comprising: i) a plurality of cathodes, each cathodecomposed of an active cathode material, wherein each cathode comprises acathode connection tab that extends outwardly therefrom; ii) an anodecomposed of an active anode material having a plurality of folds atspaced intervals along a length thereof, a first anode connection tabextending outwardly from within the anode, wherein at least one of theplurality of cathodes is received within one of the folds of the anode,a separator membrane residing between the anode and the cathode; iii) acurrent collector, composed of a current collector metal, incorporatedwith a portion of at least one of the active anode or cathode materials;iv) wherein the plurality of cathode connection tabs are folded overeach other thereby creating a cathode connection tab junction, aterminal lead electrically connected to the cathode tab junction; and c)an electrolyte contained within the casing to activate the electrodeassembly.
 2. The electrochemical cell of claim 1 further comprising aterminal pin that extends from a proximal terminal pin end to a distalterminal pin end insulated from the casing by a glass-to-metal seal thatis supported by a casing lid, wherein the proximal terminal pin end ispositioned within the casing electrically connected to the connectiontab junction and the distal terminal pin end extends outwardly from thecasing.
 3. The electrochemical cell of claim 1 wherein the anode isformed in a serpentine-like shape that weaves between each of theplurality of cathodes.
 4. The electrochemical cell of claim wherein thefirst anode connection tab is positioned in electrical contact with aninterior surface of the casing.
 5. The electrochemical cell of claim 1wherein each of the cathode connection tabs have spaced apart first andsecond folds positioned along a length of the respective connectiontabs, the first fold positioned proximate the cathode, wherein a firsttab portion that extends distal of the first fold is oriented aboutperpendicular to the first fold, and wherein a second tab portion thatextends distal of the second fold at least partially extends over thefirst tab portion and in electrical contact therebetween.
 6. Theelectrochemical cell of claim 1 wherein the active anode materialcomprises lithium, lithium silver, lithium aluminum, lithium boron,lithium silver boron, carbon, and combinations thereof.
 7. Theelectrochemical cell of claim 1 wherein the current collector comprisesa material selected from the group consisting of titanium, aluminum,nickel, and stainless steel.
 8. The electrochemical cell of claim 1wherein the casing comprises a material selected from the groupconsisting of titanium, nickel, and stainless steel.
 9. Theelectrochemical cell of claim 1 wherein the active anode material issupported on an inside surface of the casing.
 10. The electrochemicalcell of claim 1 wherein the active anode material is supported on aportion of a surface of an inside surface of a casing lid.
 11. Theelectrochemical cell of claim 1 wherein the electrolyte comprises anonaqueous solvent and an ionically conductive salt dissolved therein.12. The electrochemical cell of claim 1 wherein each of the plurality ofthe cathodes is of a plate-like structure.
 13. The electrochemical cellof claim 1 wherein a weld joint joins the plurality of folded cathodeconnection tabs together at the junction.
 14. An electrochemical cell,comprising: a) a casing of electrically conductive material; b) anelectrode assembly comprising first and second opposite polarityelectrodes housed inside the casing in electrochemical association witheach other and having a separator disposed therebetween, wherein each ofthe electrodes includes a current collector; c) an electrolyteactivating the first and second electrodes; d) the first electrodehaving a serpentine configuration comprising a plurality of successivefolds, the second opposite polarity electrodes positioned within thefirst electrode folds, wherein the second electrodes comprising a secondelectrode tab that outwardly extends therefrom, and wherein the firstelectrode comprises a first electrode tab that outwardly extends fromwithin the first electrode; e) wherein the second electrode tabs arefolded together thereby forming a second electrode tab junction, a leadelectrically connected to the second electrode junction and wherein thefirst electrode tab is electrically connected to an interior surface ofthe conductive casing; and f) a terminal having spaced apart proximaland distal terminal ends insulated from the casing, wherein the proximalterminal end is electrically connected to the second electrode tabjunction and the distal terminal end outwardly ends from the casing. 15.The electrochemical cell of claim 14 wherein each of the secondelectrode tabs have spaced apart first and second folds positioned alonga length of the respective tabs, the first fold positioned proximate thesecond electrode, wherein a first tab portion extending distal of thefirst fold is oriented about perpendicular to the first fold, andwherein a second tab portion that extends distal of the second fold atleast partially extends over the first tab portion and in electricalcontact therebetween.
 16. The electrochemical cell of claim 14 whereinthe first electrode is composed of an active electrode material selectedfrom the group consisting of lithium, lithium silver, lithium aluminum,lithium boron, lithium silver boron, carbon, and combinations thereof.17. The electrochemical cell of claim 14 wherein the first or secondelectrode current collector is composed of a material selected from thegroup consisting of titanium, aluminum, nickel, and stainless steel. 18.The electrochemical cell of claim 14 wherein the casing comprises amaterial selected from the group consisting of titanium, nickel, andstainless steel.
 19. The electrochemical cell of claim 14 wherein theelectrolyte comprises a nonaqueous solvent and an ionically conductivesalt dissolved therein.
 20. The electrochemical cell of claim 14 whereineach of the plurality of second electrodes is of a plate-like structure.21. The electrochemical cell of claim 14 wherein a weld joint joins theplurality of folded second electrode tabs together at the junction. 22.A method of constructing an electrochemical cell, the method comprisingthe following steps: a) providing a casing and a lid; b) providing anelectrode assembly, the electrode assembly comprising: i) a plurality ofcathodes, each cathode composed of an active cathode material, whereineach cathode comprises a cathode connection tab that extends outwardlyfrom within the cathode; ii) an anode composed of an active anodematerial having a plurality of folds at spaced intervals along a lengththereof, a first anode connection tab extending outwardly from withinthe anode, wherein at least one of the plurality of cathodes is receivedwithin one of the folds of the anode, and a separator membrane residingbetween the anode and the cathode; and c) folding the plurality ofcathode connection tabs over each other and positioning a terminal leadwithin the folds of the cathode connection tabs; d) joining theplurality of folded cathode connection tabs together thereby forming acathode connection tab junction; e) positioning the electrode assemblyin the casing such that the first anode connection tab is in electricalcontact with an interior surface of the casing; g) sealing the electrodeassembly within the casing with the lid and filling the casing with anelectrolyte to activate the electrode assembly.
 23. The method of claim22 including providing a terminal pin having a proximal pin end thatextends to a distal terminal pin end that is supported and electricallyisolated from the casing, wherein the proximal terminal pin end iselectrically connected to the terminal lead within the casing and thedistal terminal pin end extends outwardly from the casing lid.
 24. Themethod of claim 22 including forming the anode in a serpentine-likestructure having the plurality of folds oriented in alternatingdirections and positioning the plurality of cathodes so that anode foldsweave around the cathodes.
 25. The method of claim 22 including foldingthe plurality of cathode connection tabs at a first location proximatethe respective cathode in a first direction thereby creating a firstfold in which a first tab portion of the plurality of the connection tabextends about perpendicular from the first fold and folding theplurality of connection tabs at a second location, distal of the firstfold thereby creating a second fold in which a second tab portionextends over the first tab portion.
 26. The method of claim 22 includingproviding the active anode material comprised of lithium, lithiumsilver, lithium aluminum, lithium boron, lithium silver boron, carbon,and combinations thereof.
 27. The method of claim 22 including providingthe current collector composed of a material selected from the groupconsisting of titanium, aluminum, nickel, and stainless steel.
 28. Themethod of claim 22 including providing the casing composed of a materialselected from the group consisting of titanium, nickel, and stainlesssteel.
 29. The method of claim 22 including supporting the active anodematerial on a portion of an interior surface of the casing.
 30. Themethod of claim 22 including supporting the active anode material on aportion of an inside surface of the lid.
 31. The method of claim 22including providing the electrolyte composed of a nonaqueous solvent andan ionically conductive salt dissolved therein.
 32. The method of claim22 including providing the plurality of cathodes having a plate-likestructure.